Faux stone concrete panel and method for making same

ABSTRACT

A wall or panel has a thin concrete layer with a cross-sectional contour having protrusions and indentations forming other objects, such as stone work, brick or wood. A reinforcement layer may be affixed to the concrete layer to provide tensile strength and impact resistance to the concrete layer. A foam layer is affixed to the reinforcement layer to further reinforce the concrete layer, and so that the wall or panel is light weight. A second concrete layer or a rigid backing layer may be disposed opposite the concrete layer so that the foam is disposed therebetween. A method for forming the wall or panel includes spraying the concrete onto a mold surface which has indentations and protrusions for forming the other objects. The reinforcement layer is sprayed onto the cured concrete layer. The mold is closed and foam is introduced into the mold.

BACKGROUND OF THE INVENTION

[0001] 1. The Field of the Invention

[0002] The present invention relates generally to a light-weightconcrete panel or wall which appears as another building material, suchas stone work, brick, wood or the like. More particularly, the presentinvention relates to a panel or wall having a thin concrete face layerwith a molded contour or otherwise shaped to appear as stone work or thelike, a reinforcing elastomer layer, and an inner foam layer.

[0003] 2. The Background Art

[0004] Traditional walls have been constructed from individual stones,rocks, blocks, or bricks assembled together into the shape of a wall andheld together with mortar. One problem with traditional walls of thistype is they are typically expensive and time-consuming to construct.Another problem is their great weight.

[0005] Prior attempts have been made to simulate such stone work orbrick walls using less expensive materials and less labor-intensivemethods. One such attempt involves constructing a wall from concrete.The concrete may be molded to the shape of bricks or otherwise texturedto appear as brick. For example, concrete sidewalks have been providedwith textured surfaces by stamping a stone shape into the concretebefore it hardens.

[0006] Another such example includes manually texturing the concretebefore it cures. One problem with using concrete is that concrete tendsto have a substantially smooth texture, unlike natural stone or brick.Another disadvantage with such concrete walls is that solid concrete isalso extremely heavy.

[0007] Another attempt at providing such a textured or shaped surfaceincludes veneering, in which actual or simulated stone or brick isadhered to a conventional concrete wall. One disadvantage with veneeringis the expense, time and care involved in providing the veneer.

[0008] Another attempt simply involves making panels from plastic whichhas been molded. One disadvantage with such plastic panels is that theyoften do not provide a realistic appearance.

[0009] In addition, attempts have been made to reduce the weight ofconcrete, load bearing building elements. Such attempts include theaddition of fillers into concrete. Another technique involves bonding aplurality of laminations, including adhering a lightweight laminate tothe concrete laminate. Such techniques typically involve a foam blockonto which a concrete mixture is applied or onto which a concretelaminate is adhered. One disadvantage with these techniques is that thefoam block must be pre-shaped. Another disadvantage is that the buildingelements have thick concrete layers, and thus are heavy.

SUMMARY OF THE INVENTION

[0010] It has been recognized that it would be advantageous to develop awall or panel which has the appearance of natural stone work, rock,brick, wood, or the like, which is lightweight and durable. Theinvention provides a wall or panel with a thin concrete layer to reducethe weight of the wall or panel. The concrete layer has interior andexterior surfaces, and a cross-sectional contour. The contour projectsoutwardly to form macro projections in the exterior surface, and macroindentations in the interior surface. The contour also projects inwardlyto form macro indentations in the exterior surface, and macroprojections in the interior surface. The contour, or projections andindentations, may form natural objects, such as stone work, brick, wood,and the like. In a more detailed aspect of the invention, the concretelayer has a substantially constant thickness at the projections andindentations. In another more detailed aspect of the invention, theconcrete layer is less than approximately 0.5 inches thick to reduceweight.

[0011] A foam layer is coupled to the interior surface of the concretelayer, and has protrusions mating with the indentations in the interiorsurface of the concrete layer. The foam layer provides reinforcement tothe thin concrete layer and reduces the weight of the wall or panel. Thefoam layer may have fiber reinforcement.

[0012] In accordance with one aspect of the present invention, the wallor panel may have a thin elastomer layer affixed to the concrete layerto reinforce the concrete layer, and to provide tensile strength andimpact resistance. In a more detailed aspect of the invention, thereinforcement layer may include an elastomer layer, such as a urethanelayer. Alternatively, the reinforcement layer may include a high densityfoam, and the foam layer may include a low density foam. Thereinforcement layer may include fiber reinforcement.

[0013] In accordance with another aspect of the present invention, thewall or panel may have a rigid backing layer spaced-apart from theelastomer layer, with the foam layer disposed between, and affixed to,the elastomer layer and backing layer to further reinforce the concretelayer and making the wall or panel lightweight.

[0014] The rigid backing layer may be a second concrete layerspaced-apart from and opposite the first concrete layer. The secondconcrete layer may have a similar cross-sectional contour.

[0015] The wall or panel may be configured to be free-standing fencingstructures. Alternatively, the wall or panel may be configured as afacade to be affixed to an exterior wall of a building.

[0016] A method for making the wall or panel includes providing a moldhaving an inner mold surface with macro indentations and macroprotrusions. A wet mixture of concrete material is applied to the innermold surface of the mold to form a concrete layer with a cross-sectionalcontour corresponding to the indentations and protrusions of the innermold surface. Preferably, the concrete material is sprayed onto theinner mold surface. Preferably, the wet mixture of concrete material isapplied in a substantially constant thickness at the projections andindentations. The concrete material is cured until dry.

[0017] Foam is introduced into the mold to form a foam layer secured tothe cement layer with the foam having protrusions mating with theconcrete layer. The mold provides support to the concrete layer as thefoam expands. The secured concrete and foam layers are removed from themold.

[0018] In accordance with one aspect of the method of the presentinvention, the layer of reinforcement material is applied to theconcrete layer prior to introducing the foam to form a reinforcementlayer. Preferably, the reinforcement layer is sprayed onto the curedconcrete layer.

[0019] In accordance with another aspect of the method of the presentinvention, the rigid backing layer is spaced-apart from the mold surfaceprior to introducing the foam into the mold. Alternatively, the rigidbacking layer may be applied to the foam layer.

[0020] In accordance with another aspect of the method of the presentinvention, the mold may be disposed in a vertical orientation, eitherthroughout the process, or just before the foam is introduced into themold. Thus, the wall or panel is vertically oriented to facilitatehandling and conserve space.

[0021] Additional features and advantages of the invention will be setforth in the detailed description which follows, taken in conjunctionwith the accompanying drawing, which together illustrate by way ofexample, the features of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022]FIG. 1a is a perspective view, partially in section, of a wall orpanel in accordance with the present invention;

[0023]FIG. 1b is a more detailed, partial cross-sectional view of thewall or panel shown in FIG. 1a;

[0024]FIG. 2a is a partial perspective view, partially in section, ofanother wall or panel in accordance with the present invention;

[0025]FIG. 2b is a more detailed, partial cross-sectional view of thewall or panel shown in FIG. 2a;

[0026]FIG. 3 is a partial cross-sectional view of another wall or panelin accordance with the present invention;

[0027]FIG. 4 is a partial cross-sectional view of another wall or panelin accordance with the present invention;

[0028]FIG. 5 is a partial cross-sectional view of another wall or panelin accordance with the present invention;

[0029]FIG. 6 is a perspective view of an embodiment of a mold inaccordance with the present invention, shown in an open configuration;

[0030]FIG. 7 is a perspective view of the mold of FIG. 6 shown in anclosed configuration;

[0031]FIG. 8 is a perspective view of another embodiment of a mold inaccordance with the present invention, shown in an open configuration;

[0032]FIG. 9 is a perspective view of the mold of FIG. 8 shown in anclosed configuration;

[0033]FIGS. 10a-10 b are schematic views of a method in accordance withthe present invention; and

[0034]FIG. 11 is a schematic view of a method in accordance with thepresent invention.

DETAILED DESCRIPTION

[0035] For the purposes of promoting an understanding of the principlesof the invention, reference will now be made to the exemplaryembodiments illustrated in the drawings, and specific language will beused to describe the same. It will nevertheless be understood that nolimitation of the scope of the invention is thereby intended. Anyalterations and further modifications of the inventive featuresillustrated herein, and any additional applications of the principles ofthe invention as illustrated herein, which would occur to one skilled inthe relevant art and having possession of this disclosure, are to beconsidered within the scope of the invention.

[0036] As illustrated in the Figures, walls or panels in accordance withthe present invention are shown which are configured to appear as otherobjects or natural objects, including for example, stone work, rock,brick, or wood, and the like, and which are lightweight and durable. Asused herein, the terms “wall” and “panel” are used broadly to refer towalls or panels which may be used in building construction systems asfacades, and walls used in fence systems.

[0037] Referring to FIGS. 1a and 1 b, a wall or panel indicatedgenerally at 10 in accordance with the present invention is shownconfigured as a wall in a fencing system. Thus, the wall or panel isoriented in a vertical orientation and configured to be free standing.The wall or panel 10 includes at least one thin concrete layer, such asfirst thin concrete layer 14. The concrete layer 14 has an exteriorsurface 18 which faces outwardly to be seen, and an opposite interiorsurface 22 which faces inwardly.

[0038] The concrete layer 14 advantageously has a cross-sectionalcontour which projects outwardly to form projections 26 in the exteriorsurface 18, and indentations 30 in the interior surface 22. In addition,the cross-sectional contour projects inwardly to form indentations 34 inthe exterior surface 18 and projections 38 in the interior surface 22.Thus, the exterior surface 18 includes projections 26 and indentations34, while the interior surface 22 includes indentations 30 whichcorrespond to the protrusions 26 in the exterior surface 18, andprotrusions 38 which correspond to indentations 34 in the exteriorsurface 18.

[0039] The projections and indentations are “macro-projections” and“macro-indentations,” respectively, meaning they are sized to produce anarchitectural effect which is visible from a distance, as opposed tosurface or material irregularities. The projections 26 and indentations34 of the exterior surface 18, and thus the cross-sectional contour, aresized and shaped to appear as other objects, or natural objects,including for example, rocks, stone work, brick, wood or the like.

[0040] The concrete layer 14 has a thickness t which is substantiallyconstant throughout the portion of the concrete layer 14 including theprojections and indentations. It is of course understood that thethickness of the concrete layer 14 may vary at the indentations andprotrusions, or throughout the cross sectional contour, especially atareas of curvature. By a “substantially constant thickness,” it is meantthat the inner surface 22 of the concrete layer 14 follows the outersurface 18 as the outer surface 18 projects inwardly and outwardly, asopposed to remaining straight. Thus, the concrete layer 14 will curesubstantially evenly as discussed in greater detail below. The thicknesst of the concrete layer 14 is preferably less than one inch, morepreferably less than one-half inch, and most preferably less thanone-eighth inch, to reduce the weight of the concrete layer.

[0041] The concrete layer 14 may be formed of a concrete mix whichprovides a cementitious or textured surface to appear as real stone workor brick. It will be appreciated that concrete itself has a relativelysmooth surface. Thus, the concrete mix preferably includes sand toprovide strength to the concrete, and to provide a rougher surfacetexture. In addition, the concrete mix may include a plasticizer to keepthe mixture as dry as possible. In addition, the concrete mix mayinclude a polymer to add flexibility. In addition, the concrete mix mayinclude an accelerator for faster curing. Furthermore, a coloring may beapplied to the exterior surface 18 of the concrete layer 14 to furtherprovide the desired appearance as stone work, brick, etc. For example, astone like coloring may be added to the protrusions 28 in the exteriorsurface 18, while the indentations 34 in the exterior surface 18 retainthe natural coloring of the concrete mix. In addition, color or pigmentmay be added directly to the concrete mixture.

[0042] The concrete layer 14 advantageously is thin to reduce weight ofthe wall or panel 10. In addition, the concrete layer 14, or concretemixture, preferably and advantageously is free of fiber reinforcement.Concrete is often reinforced with glass fiber, which must be a specialalkaline resistant glass fiber, which is very expensive. Thus, asubstantial cost reduction is realized without using the more expensiveglass fiber reinforced concrete. It is of course understood that theconcrete layer may be fiber reinforced.

[0043] The panel 10 may also have a second concrete layer 42 oppositeand spaced-apart from the first concrete layer 14. The second concretelayer 42 may be similar to the first concrete layer 14, and includes across sectional contour with indentations and protrusions configured toappear as stone work, brick, etc.

[0044] The wall or panel 10 advantageously has a reinforcement layer 46adjacent and affixed to the concrete layer 14. The reinforcement layer46 preferably is an elastomer layer, but may also be a foam layer, suchas a high density foam, as discussed in greater detail below. Thereinforcement or elastomer layer 46 advantageously provides tensilestrength and impact resistance to the concrete layer 14. As statedabove, the concrete layer 14 is as thin as possible to save weight, andmay lack fiber reinforcement to reduce cost. Thus, the elastomer layer46 strengthens the thin concrete layer 14, and provides tensile strengthand impact resistance to the concrete layer 14. The elastomer layer 46preferably has a thickness between 60 and 225 mils depending on thestrength required. In addition, the elastomer layer 46 may be reinforcedwith fiberglass. A less expensive fiberglass may be used in theelastomer because it does not need to be alkaline resistant.

[0045] The elastomer layer 46 has an exterior surface 50 which isdirectly affixed to the interior surface 22 of the concrete layer 14.Thus, the exterior surface 50 of the elastomer layer 46 has protrusionsand indentations which match the respective indentations and protrusionsof the inner surface 22 of the concrete layer 14. The elastomer layer 46also has an interior surface 54. The interior surface 54 of theelastomer layer 46 also has indentations which correspond to protrusionsin the exterior surface 50, and protrusions which correspond toindentations in the exterior surface 50. Thus, the elastomer layer 46has a cross-sectional contour which matches or mates with thecross-sectional contour of the concrete layer 14. In addition, theelastomer layer 46 has a thickness which is substantially consistent atthe protrusions and indentations.

[0046] The elastomer layer 46 preferably is a sprayable urethane, asdiscussed in greater detail below. The elastomer layer 46 orreinforcement layer alternatively may be epoxy or fiberglass polyester.In addition, the elastomer layer 46 may be reinforced with choppedfiberglass. Again, a less expensive fiberglass may be used in theelastomer because it does not need to be alkaline resistant. Theconcrete layer 14 protects the reinforcement layer 46 from the sun,because the reinforcement layer 46 may not be UV stable, such as withsome elastomers.

[0047] In addition, the wall or panel 10 may include a second elastomerlayer 58 affixed to the second concrete layer 42, which is similar tothe first elastomer layer 46.

[0048] The wall or panel 10 advantageously also has a foam layer 62disposed between the concrete layers 14 and 42, and the elastomer layers46 and 58. The foam layer 62 is coupled or attached to the interiorsurfaces 54 of the elastomer layers 46 and 58. The foam layer 62advantageously has protrusions 66 which extend outwardly to mate withthe indentations in the interior surface 54 of the elastomer layer 46,and may also extend into the indentations 30 in the inner surface 22 ofthe concrete layer 14. Thus, the foam layer 62 has a thickness whichvaries at the protrusions and indentations, such that the wall or panel10 is substantially solid. The concrete and elastomer layers 14 and 46may be flexible by themselves. Thus, the foam layer 62 advantageously islightweight and provides further reinforcement and stiffness to theelastomer and concrete layers 46 and 14.

[0049] The foam layer 62 may be a MDI poly-ether, polyester, orpolyether blend. The foam layer 62 may also be a poly-urea elastomer orpolyurethane. The foam layer 62 preferably is low density, or has adensity of two to five pounds. Alternatively, the foam layer 62 may havea density between two and thirty pounds. In addition, the foam layer 62may be fiber reinforced. A less expensive fiberglass may be used in thefoam because it does not need to be alkaline resistant.

[0050] The foam layer 62 advantageously provides a filler between theconcrete layers 14 and 42 to prevent unwanted voids or spaces,particularly near the concrete layer 14, which may weaken the concretelayer. In addition, the foam layer 62 advantageously bonds the oppositeconcrete layers 14 and 42 together. Furthermore, the foam layer 62provides thermal and sound insulation to the wall or panel 10.

[0051] As shown in FIG. 1a, the wall or panel 10 is configured for useas a wall of a fencing system. The wall 10 may have a perimeter border70 or raised portion to frame and enclose the protrusions 26 andindentations 34 configured to appear as stone work, brick, etc. Theborder 70 may include a base 72 configured to appear as a foundation, atop 74 configured to appear as a cap, and sides 76 configured to appearas vertical support columns. The border 70 may be configured to appearas concrete, as shown, or may also have indentations and protrusions toappear as stone work, brick, etc. The border 70 may be constructed asthe rest of the wall 10, and be formed of the thin concrete layer 14,the elastomer reinforcement layer 46, and the foam layer 62. Thus, anentire segment of the wall system may be formed of the wall 10 to belight weight and durable.

[0052] Referring to FIGS. 2a and 2 b, an alternative embodiment of awall or panel, indicated generally at 100, includes the thin concretelayer 14, and thin elastomer layer 46, as described above. In addition,the wall or panel 100 includes a rigid backing layer 104 spaced-apartfrom the concrete and elastomer layers 14 and 46. The rigid backinglayer 104 has an exterior surface 108, and an interior surface 112opposing an interior surface 54 of the elastomer layer 46. A foam layer116 is disposed between the rigid backing layer 104 and the elastomerlayer 46 or concrete layer 14. As described above, the foam layer 116includes protrusions 120 which extend into the indentations of theelastomer layer 46 and concrete layer 14. The rigid backing layer 104may be a straight or flat layer, such as a rigid panel of fiberboard, orthe like, adhered to the foam. Alternatively, the rigid backing layer104 may be a flat concrete layer or an elastomer layer.

[0053] The rigid backing layer 104 may be used in applications in whichonly a single side of the wall or panel 100 will be seen. For example,the rigid backing layer 104 may be utilized to affix the wall or panel100 to the exterior of a building to form a facade. Again, the thinconcrete layer 14 allows the wall or panel 100 to be light-weight, andthus more easily positioned, handled, secured, etc. In addition, thebacking layer 104 protects the foam layer 116.

[0054] As shown in FIG. 2a, the wall or panel 100 may be configured as afree standing fence, or may be configured as a building panel for beingaffixed to a building. In either case, the outer surface 18 of theconcrete layer 14 may have a continuous surface of protrusions 26 andindentations 34 extending over the entire surface area of the outersurface 18 of the concrete layer 14. Thus, several walls or panels 100may be positioned adjacent one another to form a continuous surface.

[0055] As stated above, the reinforcement layer 46 preferably is anelastomer layer, and most preferably a urethane layer. Alternatively, asindicated above, the reinforcement layer 46 may be a layer of highdensity foam, such as 10 to 20 pound density, while the foam layer 62 isa low density foam layer, for example, two to five pound density.

[0056] Referring to FIG. 3, an alternative embodiment of a wall or panel200 is shown with the concrete layer 14 and a rigid backing layer 104(not shown in FIG. 3) as described above. A foam layer 204 is disposedbetween the concrete layer 14 and the rigid backing layer 104. Thus, thefoam layer 204 directly attaches to the inner surface 22 of the concretelayer 14. As described above, the foam layer 204 has a varying thicknesssuch that the foam layer 204 has projections 208 which extend into theindentations 30 in the inner surface 22 of the concrete layer 14. Thefoam layer 204 preferably is a high density foam for greater durabilityand strength, but may be a low density foam depending on theapplication. Thus, the high density foam layer 204 acts as both thereinforcement layer and the filler.

[0057] The wall or panel 200 may be configured to be attached to theexterior of a building as a facade. In such case, the wall or panel 200preferably is relatively thin, and thus the foam layer 204 preferably isa thin, high density foam. The foam layer 204 may have a thickness lessthan a few inches.

[0058] Referring to FIG. 4, an alternative embodiment of a wall orpanel, indicated generally at 300, has a thin concrete layer 14, a thinelastomer layer 46, and a rigid backing layer 104 as described above. Inaddition, the wall or panel 300 has a layer of rigid, high density foam304 adjacent and affixed to the elastomer layer 406, and a layer of lowdensity foam 308 disposed between the rigid backing layer 104 and thelayer of high density foam 304. The layer of high density foam 304provides additional rigidity and stiffness to the wall or panel 300,while the low density foam 308 reduces the weight of the wall or panel300.

[0059] Referring to FIG. 5, an alternative embodiment of a wall orpanel, indicated generally at 400, is shown with increased soundreduction, or noise insulation properties. The wall or panel 400 may besimilar to any of the walls or panels described hereto, and thus has atleast a thin concrete layer 14, and a foam layer 404. As describedabove, the various walls or panels preferably have a solid interior, orat least lack inadvertent voids, particularly near the concrete layer14, which may result in weak or damaged portions. The foam layer 404includes a plurality of voids 408 or cavities formed in the foam layer404 to improve the sound dampening qualities of the wall or panel 400.The cavities 408 are macro-voids, or sized to reduce sound, as opposedto the smaller voids inherent in the cell structure of the foam.

[0060] It will of course be understood that any of the walls or panelsdescribed above may have double faces or be two-sided, such as the wallor panel 10 shown in FIG. 1, with both faces being configured to appearas stone work, brick, etc. It is also understood that any of the wall orpanel members described above may have a single face which is shaped andconfigured to appear as stone work, brick, etc., and an opposite facewhich is configured to be attached to another object, or simply toremain plain, such as walls and panels 100, 200, 300, and 400, shown inFIGS. 2-5. Thus, the second concrete layer 42 in FIG. 1 may be replacedwith a rigid backing layer. Likewise, the rigid backing layers 104 inFIGS. 2-5 may be replaced with a second concrete layer which isconfigured to appear as stone work, brick or the like.

[0061] In addition, the various walls or panels described above may beconfigured to be attached to other objects or other walls or panels. Forexample, the sides of the walls or panels may be configured with tongueand groove type interconnections, with a first panel having a tongue,and a second panel having a groove, such that the tongue of the firstpanel may be inserted into the groove of an adjacent second panel tofacilitate securing adjacent panels. Such tongue and groove typeinterconnections may be formed integrally with the walls and panels. Asanother example, the panels may have inserts for interconnecting thepanels to one another, or other objects.

[0062] In addition, the various walls or panels described above maycontain other structural members to reinforce the panels or facilitateattachment of the panels to other objects, such as the exterior of abuilding. For example, elongated metal bars may be disposed in the foamlayer to provide additional structural rigidity to large panels.

[0063] The walls or panels of the present invention advantageously arelight weight and durable. Thus, the walls or panels may be easilymanufactured at a facility, easily transported, and easily arranged at abuilding site.

[0064] The present invention also involves a method for making the wallsor panels. Referring to FIG. 6, a mold, indicated generally at 500, isshown for forming the panels or walls of the present invention. The mold500 preferably has first and second mold halves 504 and 508. The mold500, and thus the mold halves 504 and 508, may be oriented vertically inorder to save space. The mold halves 504 and 508 preferably arepivotally coupled along one side, such that the mold halves 504 and 508may be pivoted with respect to one another between an open position asshown in FIG. 6 and a closed position as shown in FIG. 7.

[0065] The first mold half 504 includes an inner mold surface 512 whichincludes macro-indentations 516 and macro-protrusions 520. Theindentations and protrusions 516 and 520 are configured to produce theprotrusions 26 and indentations 34 in the concrete layer 14. Similarly,the second mold half 508 may include a second mold surface 524 which mayalso have indentations and protrusions. It is of course understood thatboth mold surfaces 512 and 524 will have indentations and protrusions toform a dual sided wall or panel 10 as shown in FIG. 1. Alternatively,only the first mold surface 512 may have indentations and protrusions ifthe mold is to be used to produce a wall or panel with a single shapedface.

[0066] As shown in FIG. 6, the mold 500 may be opened so that both moldsurfaces 512 and 524 are easily accessible. Color or pigment may beapplied to the indentations 516 in the mold surface 512. The color orpigments correspond to the desired color of the stone or brick.Alternatively, color or pigment may be added directly to the concretemixture of the concrete layer 14.

[0067] Referring to FIGS. 8 and 9 another mold 550 is shown for formingthe walls or panels of the present invention. The mold 550 preferablyhas first and second mold halves 554 and 558. The mold halves 554 and558 preferably are pivotally coupled to each other or the ground attheir bottom sides, so that the mold halves 554 and 558, may be orientedhorizontally in the open position, as shown in FIG. 8, and vertically inthe closed position, as shown in FIG. 9.

[0068] Similar to the mold 500 shown in FIGS. 6 and 7, the first moldhalf 554 of mold 550 includes the inner mold surface 512 which includesmacro-indentations 516 and macro-protrusions 520. Similarly, the secondmold half 558 may include the second mold surface 524 which may alsohave indentations and protrusions. As shown in FIG. 8, the mold 550 maybe opened so that both mold surfaces 512 and 524 are easily accessible.

[0069] Referring to FIG. 10a, a mold, such as molds 500 (FIG. 6) or 550(FIG. 8) is provided with at least the mold surface 510. Preferably, themold is initially open into an open configuration, as shown in FIG. 6 or8. Referring to FIG. 10b, a wet mixture of concrete material is appliedto at least the first mold surface 512 to form the first concrete layer14. In addition, the wet mixture of concrete material may also beapplied to the second mold surface 524 to produce the second concretesurface 42 for a double sided wall or panel. The concrete preferably issprayed, indicated by arrow 580, onto the mold surface 512 with asprayer in a thin layer preferably between one-eighth of an inch toone-half of an inch or more. As stated above, the concrete materialpreferably is applied as thinly as possibly to reduce weight. Inaddition, the concrete material preferably is free of glassreinforcement to reduce the cost associated with alkali resistantfiberglass. Alternatively, the concrete material may be reinforced withalkali resistant fiberglass.

[0070] In addition, the concrete material preferably is applied to themold surface 512 in a consistent or uniform thickness at theindentations and protrusions 516 and 520. As stated above, variations inthickness may occur as a result of overlapping spray patterns, or atchanges in curvature in the mold surface 512. But wide variations inconcrete thickness preferably are avoided by refraining from filling theindentations 516 in the mold surface 512 with the concrete material.

[0071] The concrete material is then allowed to cure or harden into theconcrete layers 14 and 42. The concrete material cures more evenly dueto the constant thickness of the concrete layer 14.

[0072] Referring to FIG. 10c, a reinforcement material, such as anelastomer material, is applied to the cured concrete layer 14 (and 42)to form the reinforcement layer 46 (and 58). The elastomer material orreinforcement material preferably is sprayed onto the concrete layers 14and 42, indicated by arrow 584. In the case of an elastomer material,the elastomer material sets up almost immediately as it is applied tothe concrete layers 14 and 42. As stated above, the elastomer materialpreferably is applied in a thin layer of between 60 to 225 mils,depending on the strength required. As stated above, the concrete layers14 and 42 preferably are thin to reduce weight and lack glassreinforcement to reduce cost. Thus, the elastomer layers 46 and 58advantageously provide tensile strength and impact resistance to theconcrete layers 14 and 42. In addition, the elastomer material bonds tothe concrete layers as it is applied.

[0073] The elastomer material may include fiber reinforcement. It willbe appreciated that glass fiber reinforcement for the elastomer is muchless expensive than the special alkali resistant glass fiber requiredwhen mixed with concrete.

[0074] Referring to FIGS. 7 and 9, the mold halves 504 and 508, or 554and 558, are pivoted to the closed position, such that the mold halvesare spaced-apart from one another, and a gap or space 528 formed betweenthe concrete layers 14 and 42 and elastomer layers 46 and 58. Referringto FIG. 1d, foam is then introduced into the mold 500 (FIG. 7) or 550(FIG. 9), or the space 528 between the mold halves 504 and 508 (FIG. 7),or 554 and 558 (FIG. 9), as indicated by arrow 588. Preferably, the foamis an expandable foam which expands to fill the space 528 between theconcrete layers 14 and 42 and elastomer layers 46 and 58. As the foammaterial expands, it creates the protrusions 66 which extend into theindentations 30 in the concrete layer 14. The foam stiffens the paneland further reinforces the concrete layers 14 and 42. The foampreferably is a low density foam between two and five pounds to belightweight. In addition, glass reinforcement may be added to the foam.Again, it will be appreciated that glass reinforcement for foam is muchless expensive than a special alkali resistant glass reinforcementrequired for concrete.

[0075] The mold 500 or 550 may then be opened and the resulting panel,or combined concrete layers 14 and 42, elastomer layers 46 and 58, andfoam layer 62, removed.

[0076] It will be noted that the mold 500 preferably is orientedvertically in order to save space and facilitate handling, thus reducingthe need for large equipment to lift and handle heavy molds. Inaddition, the vertically oriented molds which pivot open allow workerseasy access to the interior of the molds. Alternatively, the mold 550 ispreferably oriented horizontally while the concrete is applied toprevent the concrete from running, but vertically while the foam isinjected. In addition, the vertically oriented molds 500 and 550 resultin vertically oriented walls or panels, again saving space.

[0077] The method and molds described above also may also be used tomanufacture a single sided panel. The concrete and elastomer materialsare applied to a single sided mold, as described above. The second moldsurface 524 may be flat, or may not have the indentations andprotrusions to form stone work, brick, or the like as in the first moldsurface 512. Thus, when the mold is closed, a gap or space is formedbetween the mold halves or between the elastomer layer 46 and the secondmold surface 524. Thus, the foam material is introduced into the moldand expands between the elastomer layer 46 and the second mold surface524. The resulting panel may be removed and a rigid backing layer 104,such as plywood or the like, may be adhered to the exposed foam surface.Alternatively, an elastomer material or the like may be added to theexposed foam layer, forming the rigid backing layer.

[0078] The concrete and elastomer layers 14 and 46 by themselves arerelatively flexible. Therefore, the molds 500 and 550, or mold halves504 and 508, 554 and 558, provide rigidity to the concrete and elastomerlayers 14 and 46 as the foam material expands.

[0079] Alternatively, the rigid backing material 104, such as a plywoodsheet, may be placed in the mold adjacent the second mold surface 524such that the foam material is introduced between the elastomer layer 46and the rigid backing layer 104 so that the foam bonds to the rigidbacking layer 104 in the mold itself.

[0080] Alternatively, a concrete material may be applied in a flat layerto the second surface 524 of the mold, and foam introduced so that theresulting wall or panel has a rigid backing layer 104 of concrete formedin the foam material.

[0081] Alternatively, the reinforcement layer may be formed by applyinga high density foam material directly to the interior surface 22 of theconcrete layer 14 and then introducing a lightweight foam material intothe mold.

[0082] It is of course understood that the molds may have a single moldhalf. In addition, the rigid backing layer 104, such as a plywood layer,may be utilized as the second mold half.

[0083] Referring to FIG. 11, a plurality of molds 600 may be disposed ona transfer system 604, such as a moving conveyor, etc., and movedthrough a plurality of stations, indicated by arrow 608. At a firststation 612, the concrete mixture may be applied 580 to the mold 600.The mold 600 is then moved to a curing station 616 where the concretemixture is cured. The curing station 616 may be on the transfer system604, or the molds may be removed from the transfer system 604 to aseparate curing station 620. The mold 600 may then be moved to areinforcing station 624 where a reinforcement material, such as theelastomer material, is applied 584 to the concrete layer 14. The mold600 is then moved to a foam and/or backing layer station 628 where thefoam material is applied to the concrete and/or reinforcement layers 14and 46, and the backing layer 104 is applied. The foam material may beapplied, and then the backing layer 104 may be positioned by a press 632as shown. The foam and backing layer 104 may be applied at the samestation 628, as shown, or at different stations. In addition, the wallsor panels may be removed from the mold 600 at a different station.Alternatively, the mold 600 may be moved directly from the curingstation 616 or 620 to the foam and/or backing layer station 628. Thetransfer system 604 and plurality of molds 600 facilitate manufacturinglarger quantities of walls or panels, and speeds manufacturing.

[0084] It is to be understood that the above-described arrangements areonly illustrative of the application of the principles of the presentinvention. Numerous modifications and alternative arrangements may bedevised by those skilled in the art without departing from the spiritand scope of the present invention and the appended claims are intendedto cover such modifications and arrangements. Thus, while the presentinvention has been shown in the drawings and fully described above withparticularity and detail in connection with what is presently deemed tobe the most practical and preferred embodiment(s) of the invention, itwill be apparent to those of ordinary skill in the art that numerousmodifications, including, but not limited to, variations in size,materials, shape, form, function and manner of operation, assembly anduse may be made, without departing from the principles and concepts ofthe invention as set forth in the claims.

What is claimed is:
 1. A panel comprising: a) a concrete layer havinginterior and exterior surfaces, and a cross-sectional contour which (i)projects outwardly to form macro projections in the exterior surface andmacro indentations in the interior surface, and (ii) projects inwardlyto form macro indentations in the exterior surface and macro projectionsin the interior surface; and b) a foam layer, coupled to the interiorsurface of the concrete layer, having protrusions mating with theindentations in the interior surface of the concrete layer.
 2. A panelin accordance with claim 1, wherein the projections and indentations aresized and shaped to appear as another object.
 3. A panel in accordancewith claim 1, wherein the projections and indentations are sized andshaped to appear as another object selected from the group consistingof: rock, stone work, brick, and wood.
 4. A panel in accordance withclaim 1, wherein the concrete layer has a substantially constantthickness at the projections and indentations.
 5. A panel in accordancewith claim 1, further comprising: a rigid backing layer, spaced-apartfrom the concrete layer, having an interior surface opposing theinterior surface of the concrete layer; and wherein the foam layer isdisposed between the concrete layer and hacking layer.
 6. A panel inaccordance with claim 1, wherein the concrete layer includes a firstconcrete layer, and further comprising: a) a second concrete layer,spaced-apart from and opposite the first concrete layer, having interiorand exterior surfaces, and a cross-sectional contour which (i) projectsoutwardly to form macro projections in the exterior surface and macroindentations in the interior surface, and (ii) projects inwardly to formmacro indentations in the exterior surface and macro projections in theinterior surface; and wherein the foam layer is coupled to the interiorsurface of both of the first and second concrete layers, and hasprotrusions mating with the indentations in the interior surface of bothof the first and second concrete layers.
 7. A panel in accordance withclaim 1, further comprising: a reinforcement layer, disposed between theconcrete layer and foam layer, and directly affixed to the concretelayer, configured to provide impact resistance and tensile strength theconcrete layer.
 8. A panel in accordance with claim 7, wherein thereinforcement layer includes an elastomer material.
 9. A panel inaccordance with claim 7, wherein the reinforcement layer includes aurethane material.
 10. A panel in accordance with claim 7, wherein thereinforcement layer includes a high density foam, and the foam layerincludes a low density foam.
 11. A panel in accordance with claim 7,wherein the reinforcement layer includes a high density foam of betweenapproximately 10-20 lbs, and the foam layer includes a low density foamof between approximately 2-5 lbs.
 12. A panel in accordance with claim7, wherein the reinforcement layer includes fiber reinforcement.
 13. Apanel in accordance with claim 1, wherein the concrete layer has athickness less than approximately 0.5 inches.
 14. A panel in accordancewith claim 1, further comprising a plurality of voids formed in the foamlayer and sized and shaped to reduce sound.
 15. A panel in accordancewith claim 1, wherein the concrete layer and foam layer are configuredto enable being affixed to an exterior wall of a building.
 16. A panelin accordance with claim 1, configured to be usable in a free-standingfencing structure.
 17. A panel comprising: a) a concrete layer; b) aelastomer layer, affixed to the concrete layer; c) a rigid backinglayer, spaced-apart from the elastomer layer; and d) a foam layer,disposed between and affixed to the elastomer layer and backing layer.18. A panel in accordance with claim 17, wherein the concrete layer hasan exterior surface with protrusions and indentations, and an interiorsurface with indentations corresponding to the protrusions in theexterior surface, and protrusions corresponding to indentations in theexterior surface, the concrete layer having a substantially constantthickness at the projections and indentations; and wherein the elastomerlayer has an interior surface with indentations and protrusionscorresponding to respective indentations and protrusions of the interiorsurface of the concrete layer, the elastomer layer having asubstantially constant thickness at the projections and indentations.19. A panel in accordance with claim 17, wherein the protrusions andindentations of the exterior surface of the concrete layer are sized andshaped to appear as another object selected from the group consistingof: rock, stone work, brick, and wood.
 20. The device of claim 17,wherein the concrete layer includes a first concrete layer, and therigid backing layer includes a second concrete layer having an exteriorsurface with protrusions and indentations, and an interior surface withindentations corresponding to the protrusions in the exterior surface,and protrusions corresponding to indentations in the exterior surface,the second concrete layer having a substantially constant thickness atthe projections and indentations, and a second elastomer layer includingan interior surface with indentations and protrusions corresponding torespective indentations and protrusions of the interior surface of thesecond concrete layer, the elastomer layer having a substantiallyconstant thickness at the projections and indentations.
 21. A panel inaccordance with claim 17, wherein the reinforcement layer includes aurethane material.
 22. A panel in accordance with claim 17, wherein theelastomer layer includes fiber reinforcement.
 23. A panel in accordancewith claim 17, wherein the concrete layer has a thickness less thanapproximately 0.5 inches.
 24. A panel in accordance with claim 17,configured to enable being affixed to a wall of a building.
 25. A panelin accordance with claim 17, configured to be usable in a free-standingfencing structure.
 26. A method for forming a panel, comprising thesteps of: a) providing a mold having an inner mold surface with macroindentations and macro protrusions; b) applying a wet mixture ofconcrete material to the inner mold surface of the mold to form aconcrete layer including a cross-sectional contour corresponding to theindentations and protrusions of the inner mold surface; c) curing theconcrete material until dry; d) introducing foam into the mold to form afoam layer secured to the cement layer with the foam having protrusionsmating with the concrete layer; and e) removing the secured concrete andfoam layers from the mold.
 27. A method in accordance with claim 26,wherein the step of providing the mold further includes providing a moldwith indentations and protrusions sized and shaped to create anotherobject selected from the group consisting of: rock, stone work, brick,and wood.
 28. A method in accordance with claim 26, wherein the step ofapplying the wet mixture of concrete mixture further includes applyingthe wet mixture of concrete material in a substantially constantthickness at the projections and indentations.
 29. A method inaccordance with claim 26, further comprising the step of placing a rigidbacking layer spaced-apart from the mold surface prior to introducingthe foam into the mold.
 30. A method in accordance with claim 26,further comprising the step of applying a rigid backing layer to thefoam layer.
 31. A method in accordance with claim 26, further comprisingthe steps of: a) applying a layer of reinforcement material to theconcrete layer prior to introducing the foam to form a reinforcementlayer; and b) wherein the step of introducing the foam further includesintroducing the foam into the mold to form a foam layer secured to thereinforcement layer.
 32. A method in accordance with claim 26, furthercomprising the steps of: a) applying a layer of elastomer material tothe concrete layer prior to introducing the foam to form an elastomerlayer; and b) wherein the step of introducing the foam further includesintroducing the foam into the mold to form a foam layer secured to theelastomer layer.
 33. A method in accordance with claim 26, furthercomprising the steps of: a) applying a layer of high density foam to theconcrete layer prior to introducing the foam to form a reinforcementlayer; and b) wherein the step of introducing the foam further includesintroducing a low density of foam into the mold to form a low densityfoam layer secured to the reinforcement layer.
 34. A method inaccordance with claim 26, wherein the step of applying a wet mixture ofconcrete material further includes applying the wet mixture of concretematerial in a layer having a thickness less than approximately 0.5inches.
 35. A method in accordance with claim 26, wherein the step ofproviding the mold further includes providing the mold in a verticalorientation.
 36. A method in accordance with claim 26, wherein the stepof applying a wet mixture of cement material further includes sprayingthe wet mixture of cement material onto the inner mold surface.
 37. Amethod in accordance with claim 26, wherein the step of introducing foaminto the mold further includes introducing an expandable foam into themold which expands to fill the indentations in the inner mold surface.38. A method in accordance with claim 26, wherein the step of providinga mold further includes providing a mold with a second mold surfaceopposing the inner mold surface; and wherein the step of introducingfoam into the mold further includes introducing an expandable foambetween the concrete layer and second mold surface.
 39. A method inaccordance with claim 26, wherein the step of providing a mold furtherincludes providing a mold with a second mold surface pivotally coupledto the inner mold surface such that the inner mold surface and secondmold surface pivot between an open position and a closed position inwhich the mold surfaces oppose one another; and further including thesteps of: opening the mold prior to applying the wet mixture of cementmaterial; and closing the mold prior to introducing the foam.
 40. Amethod in accordance with claim 26, wherein the step of providing themold further includes providing a mold with a second mold surface havingindentations and protrusions; and wherein applying the wet mixture ofconcrete material further includes applying a wet mixture of concrete toboth the inner mold surface to form a first cement layer and the secondmold surface to form a second cement layer; and wherein introducing thefoam into the mold further includes introducing the foam between thefirst and second foam layers to form a foam layer secured to bothconcrete layers.
 41. A method in accordance with claim 26, furthercomprising the step of: moving the mold with a transfer system through aplurality of different stations for applying the concrete mixture,curing the concrete mixture, and introducing the foam.
 42. A method forforming a panel, comprising the steps of: a) providing a mold having aninner mold surface with macro indentations and macro protrusions; b)applying a wet mixture of concrete material to the inner mold surface ofthe mold to form a concrete layer; c) curing the concrete material untildry; d) applying a layer of reinforcement material to the cured concretelayer to form a reinforcement layer; e) introducing foam into the moldto form a foam layer secured to the reinforcement layer; and f) removingthe secured concrete, reinforcement and foam layers from the mold.
 43. Amethod in accordance with claim 42, wherein applying the wet mixture ofconcrete further includes applying the wet mixture of concrete in asubstantially constant thickness at the indentations and protrusions;and wherein applying the reinforcement material further includesapplying the reinforcement material in a substantially constantthickness at the indentations and protrusions.
 44. A method inaccordance with claim 42, wherein the step of providing the mold furtherincludes providing a mold with indentations and protrusions sized andshaped to create another object selected from the group consisting of:rock, stone work, brick, and wood.
 45. A method in accordance with claim42, further comprising the step of placing a rigid backing layerspaced-apart from the mold surface prior to introducing the foam intothe mold.
 46. A method in accordance with claim 42, further comprisingthe step of applying a rigid backing layer to the foam layer.
 47. Amethod in accordance with claim 42, wherein applying the reinforcementmaterial further includes applying a layer of elastomer material to thecement layer to form an elastomer layer.
 48. A method in accordance withclaim 42, wherein the step of applying the wet mixture of concretematerial further includes applying the wet mixture of concrete materialin a layer having a thickness less than approximately 0.5 inches.
 49. Amethod in accordance with claim 42, wherein the step of applying the wetmixture of cement material further includes spraying the wet mixture ofcement material onto the inner mold surface.
 50. A method in accordancewith claim 42, wherein the step of applying the reinforcement materialfurther includes spraying the reinforcement material onto the curedcement layer.
 51. A method in accordance with claim 42, wherein the stepof introducing foam into the mold further includes introducing anexpandable foam into the mold which expands to fill the indentations inthe inner mold surface.
 52. A method in accordance with claim 42,wherein the step of providing a mold further includes providing a moldwith a second mold surface opposing the inner mold surface; and whereinthe step of introducing foam into the mold further includes introducingan expandable foam between the concrete layer and second mold surface.53. A method in accordance with claim 42, wherein the step of providinga mold further includes providing a mold with a second mold surfacepivotally coupled to the inner mold surface such that the inner moldsurface and second mold surface pivot between an open position and aclosed position in which the mold surfaces oppose one another; andfurther including the steps of: opening the mold prior to applying thewet mixture of concrete material; and closing the mold prior tointroducing the foam.
 54. A method in accordance with claim 42, whereinthe step of providing the mold further includes providing a mold with asecond mold surface having indentations and protrusions; and whereinapplying the wet mixture of cement material further includes applying awet mixture of cement to both the inner mold surface to form a firstconcrete layer and the second mold surface to form a second concretelayer; and wherein introducing the foam into the mold further includesintroducing the foam between the first and second concrete layers toform a foam layer secured to both concrete layers.